GE Fanuc Automation

Computer Numerical Control Products

Series 16i / 18i / 160i / 180i – Model A

Series 21i / 210i – Model A

Startup Guide

B-63003EN-2/02 May 2000

 Preface

Thank you for choosing the GE Fanuc i-series for your precision machine tool control
applications. Before you begin assembling the control system, please take your time to unpack
the control components while keeping the following things in mind:

• Hold on to all documentation and shipping papers that came with the system. Please
confirm that you have received all of the manuals you requested.
• Verify that all the items listed on the bill of material have been received.
Occasionally, the same part may have two different order numbers, with one number
appearing on the paperwork and a different number on the part. For example, a spare fuse
identified on the paperwork as A06B-6066-K207 is actually labeled A60L-0001-0175.
• Visually inspect the parts for damage. Even though GE Fanuc carefully packs your
control before shipment, you should check for damaged connectors and cracked or broken
plastic parts.

• If you would like a copy of the startup ladder mentioned in Chapter 3, please contact
your GE Fanuc sales engineer.

Note
This startup guide was written to cover the GE Fanuc 16i, 18i, and 21i
controls. To keep this document as general as possible, we will refer to these
as the control or control unit throughout this manual.

Let’s get started . . .

Assembling the 16i/18i/21i !

B-63003EN-2/01 iii
 Contents

Chapter 1

Assembling the 16i/18i/21i ................................................................................................................. 1-1

Section 1 Layout of Connectors ...................................................................... 1-2
The 16i/18i/21i Control ......................................................................................................... 1-2
The Servo Power Supply Module .......................................................................................... 1-4
The Servo Amplifier Module................................................................................................. 1-5
The Spindle Amplifier Module.............................................................................................. 1-6
I/O Unit Model A................................................................................................................... 1-7
GE Fanuc Operator’s Panel for i-Series................................................................................. 1-8
Section 2 Connection Diagram...................................................................... 1-10
Section 3 Making the Connections................................................................ 1-11
Connecting the Control to the MDI Unit ............................................................................. 1-11
Power Connections to the Power Supply Module ............................................................... 1-12
Connecting the control power to the power supply module ................................................ 1-13
Connecting the Control to the Servo Amplifiers ................................................................. 1-14
Connecting the Control to the Spindle Amplifiers .............................................................. 1-16
Connecting the Power Supply Module to the Amplifiers.................................................... 1-17
Connecting the Motor Encoder to the Servo Amplifier....................................................... 1-19
Connecting Motor Power to the Servo Amplifier................................................................ 1-19
Connecting the Motor Pulse Generator to the Spindle Amplifier ....................................... 1-25
Connecting Motor Power to the Spindle Amplifier............................................................. 1-25
Connecting the E-Stop and Main Power Control Signal ..................................................... 1-27
Connecting the Control to the I/O Link ............................................................................... 1-29
Connecting 24V DC Power to the Control & Operator’s Panel .......................................... 1-35
Grounding the 16i/18i/21i Machine Tool Control System .................................................. 1-37

Configuring the 16i/18i/21i................................................................................................................ 2-1

Section 1 Setting the Initial Parameters ......................................................... 2-2
Types of Parameters............................................................................................................... 2-2
Entering Parameter Values from the MDI Panel ................................................................... 2-3
Parameter Write Enable (PWE) ............................................................................................. 2-4
Removing the Alarms ............................................................................................................ 2-5
Cycle Power ........................................................................................................................... 2-9
Section 2 The Servo Setting Screen .............................................................. 2-10
Determining the Motor ID Number ..................................................................................... 2-11
Setting CMR and the Flex Feed Gear .................................................................................. 2-12
Other Parameters on the Servo Setting Screen .................................................................... 2-18
Putting It Together ............................................................................................................... 2-19

Installing the Startup Ladder ........................................................................................................... 3-1

Section 1 Overview........................................................................................... 3-2

B-63003EN-2/012 v
Contents
Machine Control .................................................................................................................... 3-2
The Ladder Diagram .............................................................................................................. 3-3
PMC Addresses...................................................................................................................... 3-4
PMC Instructions ................................................................................................................... 3-5
The Advantages of Ladder Language Programming ............................................................. 3-6
Section 2 Installing the Startup Ladder......................................................... 3-7

Powering Up the Entire System ........................................................................................................ 4-1

Setting FSSB parameters ....................................................................................................... 4-2
Enable Write Protect (Optional) ............................................................................................ 4-4
Powering up the Entire System.............................................................................................. 4-5
Jogging the Servo Motors ...................................................................................................... 4-6
Troubleshooting Your System ............................................................................................... 4-6

vi 16i/18i/21i Startup Guide - May 2000 B-63003EN-2/012

 Chapter Assembling the 16i/18i/21i
1

This chapter describes power connections, grounding requirements, and the essential cabling
between the separate devices in a 16i/18i/21i control system. Please remember to keep in mind
the following guidelines while assembling your system:
• Always make sure connectors lock into the sockets.
• The control unit, operator’s panel connection unit, and I/O Unit Model A require a
regulated 24V DC power source. This power source is not provided by GE Fanuc.
• Do not overlook the importance of proper grounding for the control system.
Grounding information is included in this chapter.
• There are many different combinations of models, motors, servos, spindles, and
options available with the control. Although this manual does not address all of these
combinations, it should serve as a guide to step you through the startup procedure. If
you need more detailed connection information than what is contained in this chapter,
please refer to the appropriate GE Fanuc manual(s):

16i / 18i / 160i / 180i - Model A Connection Manual (publication no. B-63003EN)
21i / 210i - Model A Connection Manual (publication no. B-63083EN)
Control Motor Amplifier α series Description Manual (publication no. B-65162E)

B-63003EN-2/01 1-1
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Section 1 Layout of Connectors

Before beginning, take time to familiarize yourself with the connector layouts on the next
several pages. It might help to make copies and spread them out in front of you to keep from
having to constantly flip back and forth through the pages.

The 16i/18i/21i Control

Back View
Figure 1-1 below identifies the connectors located on the back of the control.
top of control

bottom of control

Figure 1 - 1. Layout of connectors on the back of the control

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Bottom Side View

Figure 1-2 below identifies the connectors as seen from the bottom of the control. As you can
see, the connector labeled COP10A is hidden behind the yellow casing on the control and may
be tricky to find.

LCD - front side of control

Figure 1 - 2. Layout of connectors as seen from the bottom of the control

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The Servo Power Supply Module

Figure 1-3 below identifies the connectors located on the front panel of a typical power supply
module:

L+

L-

CX1A CX1B

CX2B

CX2A

JX1B

CX3 CX4
MCC ESP

L1 L2 L3

Figure 1 - 3. Layout of connectors on the face of a typical power supply module

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The Servo Amplifier Module

Figure 1-4 below identifies the connectors located on the front panel of a 3-axis servo amplifier
module. GE Fanuc servo amplifiers also come in 1-axis and 2-axis models.

L+

L-

CX2B
CX2A
JX5
JX1A

JX1B ENC1
JF1

ENC2
JF2

ENC3
JF3
COP10B

COP10A

UL VL UM VM UN VN

WL WM WN

Figure 1 - 4. Layout of connectors on the face of a 3-axis servo amplifier

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The Spindle Amplifier Module

Figure 1-5 below identifies the connectors located on the front panel of a typical spindle
amplifier module :

L+

L-

CX1A CX1B

CX2B

CX2A
JX4

JX1A

JX1B

JY1

JA7B

JA7A

JY2

JY3

JY4

JY5

L1 L2 L3

Figure 1 - 5. Layout of connectors on the face of a typical spindle amplifier

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I/O Unit Model A

The Model A I/O unit consists of a base unit, interface module, and I/O modules. Five-slot and
ten-slot base units are available as well as vertical and horizontal modules.
Figure 1-6 below identifies the different units and the connectors located on the interface
module.

Interface Module I/O Modules Base Unit

PWR LINK
BA0
BA1

AIF01A

JD1B JD1A

CP32 JD2

FANUC

Figure 1 - 6. Layout of connectors on the Model A I/O Unit

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GE Fanuc Operator’s Panel for i-Series

Figure 1-7a to 1 – 7e below show the font panel of the main and sub panels for i-series. ON and
OFF push-buttons are provided to switch 24V DC power for the control and other machine
devices.

Figure 1 - 7a. GE Fanuc Main Panel B A02B-0236-C231

Figure 1 - 7b. Figure 1 - 7c.

GE Fanuc Sub Panel B A02B-0236-C233 GE Fanuc Sub Panel C A02B-0236-C234

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Figure 1 - 7d. GE Fanuc Main Panel B + Sub Panel B

Figure 1 - 7e. GE Fanuc Main Panel B + Sub Panel C

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Section 2 Connection Diagram

The block diagram below is meant to give to you an overall perspective of the main
connections involved in a GE Fanuc 16i/18i/21i machine tool control system. Although it
illustrates typical connections encountered in most applications, this diagram does not address
every single connection possibility.
The left side of the diagram represents the control, and the right side illustrates the servos,
spindles, I/O connections, etc. Please note that the terminal block labels TB1 and TB2 on this
diagram consist of multiple terminal screws which will be discussed in more detail in this
chapter.

16i/18i/21i control unit

24V-IN (CP1A) 24V DC power

MDI unit
CK2 operator’s panel I/O module
MDI (CA55) CK1
manual pulse generator
DC 24V
CPD1 JA3
JD1B CE53 operator’s
I/O Link (JD1A) panel
JD1A CE54
DC 24V
CP32 I/O unit power
magnetics
JD1B model A
cabinet
JD1A

to next I/O module model A I/O unit

SPDL (JA41) circuit breaker
AC reactor
AC 200V
MCC
AC 200V
circuit breaker
CX1A TB2 CX3
CX4
CX1B TB1 JX1B power supply module

spindle amplifier module

CX1A TB1 CX2A JX1A

serial spindle
JY2
motor
CXIB TB1 CX2B JXIB TB2

to 2nd spindle servo amplifier module

TB1 CX2A CX2B 1st axis servo

COP10A TB2 motor
FSSB (COP10A)
COP10B JF1
TB1 CX2B JXIB
2nd axis servo
COP10A TB2 motor
COP10B JF2

to 3rd servo

Figure 1 - 8. Total connection diagram for the 16i/18i/21i machine tool control system

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Section 3 Making the Connections

To make this section easier to read, all part numbers have been underlined and all connector
names written in bold.

Connecting the Control to the MDI Unit

The MDI unit is the manual data input device. Basically, it is the keyboard used to input data
such as programs and parameters into the CNC. A standard MDI unit is available for each of
the i-Series controls according to the specifications.
Follow these steps to connect the control to the MDI unit:
1. There are two connections required between these two units. Locate the flat, gray
cable with the blue connector. One end of this cable is already connected to the
control.
2. Insert the other end of the cable into the connector labeled CK2 on the back of the
MDI unit. Gently press the two clamps on the connector together to snap the cable
into place.
3. Find the other cable which connects the control to the MDI unit. This cable is
identified by GE FANUC part LX660-2030-T010/L500R0 (0.5 m length) or
LX660-2030-T010/L1R003 (1 m length).
Connect one end of this cable to the connector labeled CK1 on the back of the MDI unit.
4. Connect the other end to the CA55 connector located on the back of the control.

control unit

insert into CA55 flat, gray cable

insert blue connector into CK2

MDI unit
insert into CK1

Figure 1 - 9. Connecting the control to the MDI unit

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Power Connections to the Power Supply Module

φ motor power line

Connecting the 3φ
Follow this procedure to connect power to the power supply module:
1. You must supply the cable to connect 200V AC to the power
supply module. See Table 1-1 below to determine the
required cable gauge for your power supply module:

Table 1 - 1. Finding a suitable cable for your power supply module

Power Supply Module Suitable Cable Gauge
Model AWG Metric
PSMR-3 12 > 3.5 mm2
PSMR-5.5, PSM-5.5 10 >5.5 mm2
PSM-11 8 >8 mm2
PSM-15 6 >14 mm2
PSM-26, PSM-30, PSM-45 4 >22 mm2

2. Connect this cable to the power supply module according to Figure 1-10 below. The
three phases and ground must be attached securely to connectors L1, L2, L3, and
Ground on the power supply module. The bottom terminal block on the power supply
module which consists of these four connectors is labeled TB2 on Figure 1-8.
3. Install the circuit breakers, MCC, and AC reactor in series between the three-phase
power source and the power supply modules. The AC reactor is provided by GE
Fanuc. You must supply the circuit breakers and MCC. See Section 4.1.12 in the
Control Motor Amplifier α series Description Manual (publication no. B-65162E)
for information on how to select the proper devices.
main power supply
3φ
200VAC
R L1

S circuit MCC AC L2
breaker reactor
T L3

Ground
bottom terminal block
TB2 on power supply
module

Figure 1 - 10. Connecting the motor power line to the power supply module

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Connecting the control power to the power supply module

In order to connect 1φ 200V AC to the power supply module, follow these steps:
1. Locate the cable you are using to connect control power
to the power supply module. This connection requires a 16
gauge (1.25 mm2) wire.
2. Locate the 3-pin connector identified as FANUC part # A02B-0120-K321.
3. Connect the first phase of your power (phase R) to pin 1 of this connector.
4. Connect the second phase of your power (phase S) to pin 2 of this connector.
5. Connect pin 3 on the connector to ground.
6. Once you have completed wiring the cable to the connector, find the connector labeled
CX1A on the face of the power supply module. Insert the connector into this slot.

main power supply

Ground
S

CX1A connector
pin layout

Figure 1 - 11. Connecting the control power to the power supply module

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Connecting the Control to the Servo Amplifiers

The control is connected to the servo amplifiers by a single optical cable known as the FANUC
Serial Servo Bus (FSSB). There is only one connection between the control and the servo
amplifiers regardless of the number of controlled axes.
Follow this procedure to connect the control to the servo amplifiers:
1. Locate the optical fiber cable which connects the control
to the servos. This cable will have one of the following
FANUC part numbers depending on its length and mounting
location:
a. Connection between modules or connection within the
same switch gear enclosure use internal cord type:
0.15m A66L-6001-0023#L150R0
0.30m A66L-6001-0023#L300R0
0.50m A66L-6001-0023#L500R0
1m A66L-6001-0023#L1R003
2m A66L-6001-0023#L2R003
3m A66L-6001-0023#L3R003
5m A66L-6001-0023#L5R003
7m A66L-6001-0023#L7R003
10 m A66L-6001-0023#L10R03

b. External cable when the cable is laid outside the

power magnetics cabinet or main unit, where it may be
pulled, rubbed or stepped on:
1m A66L-6001-0026#L1R003
5m A66L-6001-0026#L5R003
10m A66L-6001-0026#L10R03
20m A66L-6001-0026#L20R03

2. Insert one end into the connector labeled COP10A on the bottom of the back side of
the control. The connector is located behind the plastic yellow casing.
3. Insert the other end into the connector labeled COP10B on the front panel of the servo
amplifier.
4. You can connect a second servo amplifier module to the first one by running an optical
cable between COP10A of the first module and COP10B of the second module. You
can connect up to a total of 4 axes on a 21i, 6 axes on a 18i, or 8 axes on a 16i in this
manner. The part numbers for the optical cables between the servo amplifiers are
identified as per 1a. if the cable is not subject to movement during operation.

Note
If you are using a separate feedback device in addition to the built-in motor
encoder, please refer to:
Chapter 7.9 in the 16i /18i / 160i / 180i - Model A Connection Manual
Chapter 7.1 in the 21i / 210i - Model A Connection Manual

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Figure 1 - 82. The optical cable for servo amplifier connections

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Connecting the Control to the Spindle Amplifiers

We will discuss the serial spindle connection in this startup guide. If your setup involves an
analog spindle, please refer to:
Chapter 7.8 in the 16i /18i / 160i / 180i - Model A Connection Manual
Chapter 6.2 in the 21i / 210i - Model A Connection Manual

Serial Spindle Connection

To connect a serial spindle, follow these steps:
1. Locate the cable you will use to connect the control to
the spindle amplifier. This cable could be one of the
following cables:
LX660-2077-T203/L200R0 0.2 m length
LX660-2077-T203/L300R0 0.3 m length
LX660-2077-T203/L500R0 0.5 m length
LX660-2077-T203/L1R003 1.0 m length
LX660-2077-T203/L2R003 2.0 m length
LX660-2077-T203/L3R003 3.0 m length
LX660-2077-T203/L4R003 4.0 m length
LX660-2077-T203/L5R003 5.0 m length
LX660-2077-T203/L6R003 6.0 m length
LX660-2077-T203/L7R003 7.0 m length
LX660-2077-T203/L8R003 8.0 m length
LX660-2077-T203/L10R03 10.0 m length

2. Insert one end of this cable into the connector labeled JA41 on the back of the control.
3. Insert the other end into the connector labeled JA7B on the spindle amplifier module.
4. You can connect a second spindle amplifier module by running a cable from connector
JA7A on the first amplifier to JA7B on the second amplifier. You can use one of the
cables whose part numbers are listed in step 1.

Note
There are many different pulse coder connection possibilities for the GE
Fanuc α series spindle motors. The following example describes how to
connect a serial spindle if you are using the pulse generator built into the
motor. If you are using a different pulse coder configuration, please refer to
Chapter 9.3.4 in the GE Fanuc Control Motor Amplifier α series Description
Manual.

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Connecting the Power Supply Module to the Amplifiers

The Module Interface Connection

The modules are consecutively attached, or “daisy chained”, to one another through the module
interface connectors (JX..B resp. CX..B for output and JX..A resp. CX..A for input) located on
each power supply module and spindle/servo amplifier unit. The connector JX.. stands for
signal connection, and the connector CX.. stands for a power supply or emergency stop
connection. The power supply module will connect to the first amplifier, and then the first
amplifier to the second and so on.
Locate the cable you will use to connect the power supply
module to the first amplifier module. This cable kit is
identified as GE Fanuc part :
LX660-2077-T200/L300R0 300 mm length
LX660-2077-T201/L300R0 300 mm length
LX660-2077-T202/L300R0 300 mm length

LX660-2077-T200/L200R0 200 mm length

LX660-2077-T201/L200R0 200 mm length
LX660-2077-T202/L200R0 200 mm length
Insert one end of the cable LX660-2077-T200/L… into the
connector labeled JX1B on the face of the power supply
module.
5. Connect the other end of the cable into the connector labeled JX1A on the first
amplifier module.
Note
If your system has a spindle amplifier, it is normally the first connection.
6. You can add spindle/servo amplifier modules to the system by “daisy chaining” them
the same way. Just connect JX1B from the first amplifier to JX1A on the second
amplifier and so on.
7. The last amplifier in this chain will have an unused output connector (nothing plugged
into JX1B). You have to insert the terminating connector here to allow the motors to
be driven. This connector is supplied by GE Fanuc and should be connected to JX1B
on the power supply module when you receive it.

The 24V DC Connection

This power is connected as follows:
1. The cable LX660-2077-T201/L… connects the 24V DC supply
between the modules.
2. Insert one end of this cable into the connector labeled CX2B on the power supply
module.
3. Insert the other end of this cable into the connector labeled CX2A on the first
amplifier.
4. When adding amplifier modules to the system, simply connect CX2B on the first
amplifier to CX2A on the second amplifier and so on.

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The 200V AC Connection to the Spindle Amplifiers

Note
Before you continue, remember that this following connection is only made
between the power supply module and connecting spindle amplifier modules.
The servo amplifier does not require this connection.

1. The cable LX660-2077-T202/L… connects the 200V AC power

between the power supply module and the first spindle
amplifier
2. Connect the 3-pin connector on one end of the cable to the connector labeled CX1B on
the power supply module.
3. Connect the other end of the cable to the connector labeled CX1A on the first spindle
amplifier module.
4. To connect a second spindle module, just connect CX1B from the first amplifier to
CX1A on the second amplifier.

The Bus Bar Connection

The bus bars on connectors L+ and L- make up the connection labeled TB1 on Figure 1-8.
1. Find the bus bar which connects power between the
modules. The part for this piece will depend upon the
specifications of your setup.
2. Using one bar, connect the terminal screw labeled L+ on the power supply module to
the terminal screw labeled L+ on the first amplifier module. With the other bar,
connect the L- terminals on the two modules.
3. When adding on more amplifiers, just use two more bus bars to connect adjacent
modules as described in step 2.

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Connecting the Motor Encoder to the Servo Amplifier

To connect the motor encoder to the servo amplifier, follow this procedure:
1. Remove the plastic protective cap from the connector on
the motor and locate the cable for your motor. Look up
your encoder cable part # on the table below

Table 1 - 2. Motor encoder feedback cables

Usage GE Fanuc Severe Duty Cable

LX660-4077-T264/L3R003 3m
LX660-4077-T264/L4R003 4m
LX660-4077-T264/L5R003 5m
A1/3000, A2/2000, LX660-4077-T264/L6R003 6m
A3/3000AM2/2000, AM2.5/3000, LX660-4077-T264/L7R003 7m
SVM, SVU LX660-4077-T264/L8R003 8m
LX660-4077-T264/L10R03 10m
LX660-4077-T264/L12R03 12m
LX660-4077-T264/L14R03 14m
With straight Motor connector:
LX660-4077-T208/L3R003 3m
LX660-4077-T208/L4R003 4m
LX660-4077-T208/L5R003 5m
LX660-4077-T208/L6R003 6m
LX660-4077-T208/L7R003 7m
LX660-4077-T208/L8R003 8m
LX660-4077-T208/L10R03 10m
A3/3000 – A150/2000,
LX660-4077-T208/L12R03 12m
AM, AL, AC, HV Servo Motors
LX660-4077-T208/L14R03 14m
SVM
Or with elbow type motor
connector::
LX660-4077-T209/L3R003 3m
LX660-4077-T209/L4R003 4m
LX660-4077-T209/L5R003 5m
LX660-4077-T209/L6R003 6m
LX660-4077-T209/L7R003 7m
LX660-4077-T209/L8R003 8m
LX660-4077-T209/L10R03 10m
LX660-4077-T209/L12R03 12m
LX660-4077-T209/L14R03 14m

2. The cable has two distinct connectors. Plug one end into the connector labeled ENC1
JF1 on the face of the amplifier module (for the 2nd motor, use ENC2 JF2 and so on).

3. The other end of the cable is configured so that it can only be attached to one of the
two circular connectors on the motor. Go ahead and plug this side in too.

Connecting Motor Power to the Servo Amplifier

Connect the motor power to the servo amplifier using the following procedure:

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1. Find the cable which connects the motor to the servo amplifier. Look up your cable
part on the table below:

Table 1 - 3. Cross reference of motor power cables

GE Fanuc Cables Description Application

LX660-8077-T200/L3R003 3m
LX660-8077-T200/L4R003 4m
LX660-8077-T200/L5R003 5m
LX660-8077-T200/L6R003 6m
LX660-8077-T200/L7R003 7m
LX660-8077-T200/L8R003 8m Power cable for Connection
LX660-8077-T200/L10R03 10m Servo Power between Alpha amplifier
LX660-8077-T200/L12R03 12m Supply Cable and B 1 – B 6
LX660-8077-T200/L16R03 16m A3– A6
LX660-8077-T200/L18R03 18m straight connector
LX660-8077-T200/L20R03 20m
LX660-8077-T200/L22R03 22m
LX660-8077-T200/L24R03 24m
LX660-8077-T200/L27R03 27m
LX660-8077-T200/L30R03 30m

LX660-8077-T201/L3R003 3m
LX660-8077-T201/L4R003 4m
LX660-8077-T201/L5R003 5m
LX660-8077-T201/L6R003 6m
LX660-8077-T201/L7R003 7m
Power cable for Connection
LX660-8077-T201/L8R003 8m
between Alpha amplifier
LX660-8077-T201/L10R03 10m Servo Power
and B 1 – B 6
LX660-8077-T201/L12R03 12m Supply Cable
A3– A6
LX660-8077-T201/L16R03 16m
elbow connector
LX660-8077-T201/L18R03 18m
size 18-10
LX660-8077-T201/L20R03 20m
LX660-8077-T201/L22R03 22m
LX660-8077-T201/L24R03 24m
LX660-8077-T201/L27R03 27m
LX660-8077-T201/L30R03 30m

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GE Fanuc Cables Description Application

LX660-8077-T202/L3R003 3m
LX660-8077-T202/L4R003 4m
LX660-8077-T202/L5R003 5m
LX660-8077-T202/L6R003 6m
LX660-8077-T202/L7R003 7m
LX660-8077-T202/L8R003 8m Power cable for Connection
LX660-8077-T202/L10R03 10m Servo Power between Alpha amplifier
LX660-8077-T202/L12R03 12m Supply Cable and A 12 – A 22
LX660-8077-T202/L16R03 16m straight connector
LX660-8077-T202/L18R03 18m size 22-22
LX660-8077-T202/L20R03 20m
LX660-8077-T202/L22R03 22m
LX660-8077-T202/L24R03 24m
LX660-8077-T202/L27R03 27m
LX660-8077-T202/L30R03 30m

LX660-8077-T203/L3R003 3m
LX660-8077-T203/L4R003 4m
LX660-8077-T203/L5R003 5m
LX660-8077-T203/L6R003 6m
LX660-8077-T203/L7R003 7m
LX660-8077-T203/L8R003 8m Power cable for Connection
LX660-8077-T203/L10R03 10m Servo Power between Alpha amplifier
LX660-8077-T203/L12R03 12m Supply Cable and A 12 – A 22
LX660-8077-T203/L16R03 16m elbow connector
LX660-8077-T203/L18R03 18m size 22-22
LX660-8077-T203/L20R03 20m
LX660-8077-T203/L22R03 22m
LX660-8077-T203/L24R03 24m
LX660-8077-T203/L27R03 27m
LX660-8077-T203/L30R03 30m

LX660-8077-T204/L3R003 3m
LX660-8077-T204/L4R003 4m
LX660-8077-T204/L5R003 5m
LX660-8077-T204/L6R003 6m
LX660-8077-T204/L7R003 7m
LX660-8077-T204/L8R003 8m Power cable for Connection
Servo Power
LX660-8077-T204/L10R03 10m between Alpha amplifier
Supply Cable
LX660-8077-T204/L12R03 12m and A 30 – A 40
LX660-8077-T204/L16R03 16m straight connector
LX660-8077-T204/L18R03 18m size 24-10
LX660-8077-T204/L20R03 20m
LX660-8077-T204/L22R03 22m
LX660-8077-T204/L24R03 24m
LX660-8077-T204/L27R03 27m
LX660-8077-T204/L30R03 30m

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GE Fanuc Cables Description Application

LX660-8077-T205/L3R003 3m
LX660-8077-T205/L4R003 4m
LX660-8077-T205/L5R003 5m
LX660-8077-T205/L6R003 6m
LX660-8077-T205/L7R003 7m
Power cable for Connection
LX660-8077-T205/L8R003 8m
Servo Power between Alpha amplifier
LX660-8077-T205/L10R03 10m
Supply Cable and A 30 – A 40
LX660-8077-T205/L12R03 12m
elbow connector
LX660-8077-T205/L16R03 16m
size 24-10
LX660-8077-T205/L18R03 18m
LX660-8077-T205/L20R03 20m
LX660-8077-T205/L22R03 22m
LX660-8077-T205/L24R03 24m
LX660-8077-T205/L27R03 27m
LX660-8077-T205/L30R03 30m

LX660-4078-T021/L3R003 3m
LX660-4078-T021/L4R003 4m
LX660-4078-T021/L5R003 5m
LX660-4078-T021/L6R003 6m
LX660-4078-T021/L7R003 7m
Power cable for Connection
LX660-4078-T021/L8R003 8m
Servo Power between Beta amplifier
LX660-4078-T021/L10R03 10m
Supply Cable and B 1 – B 6,
LX660-4078-T021/L12R03 12m
A C3 – A C6
LX660-4078-T021/L16R03 16m
elbow connector
LX660-4078-T021/L18R03 18m
LX660-4078-T021/L20R03 20m
LX660-4078-T021/L22R03 22m
LX660-4078-T021/L24R03 24m
LX660-4078-T021/L27R03 27m
LX660-4078-T021/L30R03 30m

LX660-4078-T026/L3R003 3m
LX660-4078-T026/L4R003 4m
LX660-4078-T026/L5R003 5m
LX660-4078-T026/L6R003 6m
LX660-4078-T026/L7R003 7m
Power cable for Connection
LX660-4078-T026/L8R003 8m
Servo Power between Beta amplifier
LX660-4078-T026/L10R03 10m
Supply Cable and B 1 – B 6,
LX660-4078-T026/L12R03 12m
A C3 – A C6
LX660-4078-T026/L16R03 16m
straight connector
LX660-4078-T026/L18R03 18m
LX660-4078-T026/L20R03 20m
LX660-4078-T026/L22R03 22m
LX660-4078-T026/L24R03 24m
LX660-4078-T026/L27R03 27m
LX660-4078-T026/L30R03 30m

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GE Fanuc Cables Description Application

LX660-4078-T024/L3R003 3m
LX660-4078-T024/L4R003 4m
LX660-4078-T024/L5R003 5m
LX660-4078-T024/L6R003 6m
LX660-4078-T024/L7R003 7m
Power cable for Connection
LX660-4078-T024/L8R003 8m Servo Power
between Beta amplifier
LX660-4078-T024/L10R03 10m Supply Cable
and B 0.5 motor connector
LX660-4078-T024/L12R03 12m without brake
non-waterproof
LX660-4078-T024/L16R03 16m
LX660-4078-T024/L18R03 18m
LX660-4078-T024/L20R03 20m
LX660-4078-T024/L22R03 22m
LX660-4078-T024/L24R03 24m
LX660-4078-T024/L27R03 27m
LX660-4078-T024/L30R03 30m

LX660-8078-T001/L3R003 3m
LX660-8078-T001/L4R003 4m
LX660-8078-T001/L5R003 5m
LX660-8078-T001/L6R003 6m
LX660-8078-T001/L7R003 7m
LX660-8078-T001/L8R003 8m Servo Power Power cable for Connection
LX660-8078-T001/L10R03 10m Supply Cable between Beta amplifier
LX660-8078-T001/L12R03 12m with brake and B 0.5 motor connector
LX660-8078-T001/L16R03 16m non-waterproof
LX660-8078-T001/L18R03 18m
LX660-8078-T001/L20R03 20m
LX660-8078-T001/L22R03 22m
LX660-8078-T001/L24R03 24m
LX660-8078-T001/L27R03 27m
LX660-8078-T001/L30R03 30m

LX660-8077-T214/L3R003 3m
LX660-8077-T214/L4R003 4m
Power cable for Connection
LX660-8077-T214/L5R003 5m
Servo Power between Alpha amplifier
LX660-8077-T214/L6R003 6m
Supply Cable and A 1 – A 2 straight type
LX660-8077-T214/L7R003 7m
without brake
LX660-8077-T214/L8R003 8m
LX660-8077-T214/L10R03 10m
LX660-8077-T214/L12R03 12m
LX660-8077-T214/L16R03 16m

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GE Fanuc Cables Description Application

LX660-8077-T213/L3R003 3m
LX660-8077-T213/L4R003 4m
LX660-8077-T213/L5R003 5m
LX660-8077-T213/L6R003 6m
LX660-8077-T213/L7R003 7m Power cable for Connection
LX660-8077-T213/L8R003 8m Servo Power between Alpha amplifier
LX660-8077-T213/L10R03 10m Supply Cable and A 1 – A 2 straight type
LX660-8077-T213/L12R03 12m with brake
LX660-8077-T213/L16R03 16m
LX660-8077-T213/L18R03 18m
LX660-8077-T213/L20R03 20m
LX660-8077-T213/L22R03 22m
LX660-8077-T213/L24R03 24m
LX660-8077-T213/L27R03 27m
LX660-8077-T213/L30R03 30m

2. One of the ends of this cable has four wires which connect to the α series servo
amplifier’s terminal strip. Connect the four wires to the corresponding amplifier
terminals labeled UL, VL, WL, and Ground. The bottom terminal block on the servo
amplifier module which consists of these connectors is labeled TB2 on Figure 1-8.

Note
Axis numbers are designated by the letters L (1st axis), M (2nd axis), and
N (3rd axis). For a motor connected to the second axis, the power cables
would be attached to amplifier terminals UM, VM, WM, and Ground.

3. Remove the plastic cap protecting the motor’s connector and attach the other end of
the cable to the motor. The motor cables are keyed and can only be properly attached
to the proper motor connection point.

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Connecting the Motor Pulse Generator to the Spindle Amplifier

This procedure assumes that you purchased the connection cable from GE Fanuc. If you
bought the connector only (FANUC part A06B-6078-K212) and chose to make this connection
yourself, please refer to Section 9.3.3 in the GE Fanuc Control Motor Amplifier α series
Description Manual (publication no. B-65162E) for a more detailed description.
To connect the motor encoder to the spindle amplifier, follow these steps:
1. Remove the square plastic cover from the spindle motor
and locate the cable for your motor. The 14m cable is
identified by GE Fanuc part:

GE Fanuc Cables Description Application

LX660-4077-T219/L3R003 3m
LX660-4077-T219/L4R003 4m
LX660-4077-T219/L5R003 5m Cable pulse generator, built-in
LX660-4077-T219/L6R003 6m Spindle feedback cable sensor Alpha spindle motors
LX660-4077-T219/L7R003 7m except A 0.5
LX660-4077-T219/L8R003 8m
LX660-4077-T219/L10R03 10m
LX660-4077-T219/L12R03 12m
LX660-4077-T219/L14R03 14m

2. Plug one end into the connector labeled JY2 on the face of the spindle amplifier
module.
3. Plug the other end into the pulse generator connector on the motor (under the square
plastic cover).

Connecting Motor Power to the Spindle Amplifier

Connect the motor power to the spindle amplifier using the following procedure:
1. Find the cable which connects the motor to the spindle amplifier. The specifications
for your cable according to spindle motor type are listed in Appendix F of the
GE Fanuc Control Motor Amplifier α series Description Manual.
2. One of the ends of this cable has four wires which connect to the α series spindle
amplifier’s terminal strip. Screw in the four wires to the amplifier terminals labeled U,

B-63003EN-2/01 Chapter 1 Assembling the 16i/18i/21i 1 - 25

 1

V, W, and Ground. The bottom terminal block on the spindle amplifier module which
consists of these four connectors is labeled TB2 on Figure 1-8.
3. Remove the square plastic cover on the spindle motor. Find the terminal screws
labeled U, V, W, and Ground and screw the other end of the four wires into the
corresponding locations. Make sure that all three phases and ground match up
properly.

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Connecting the E-Stop and Main Power Control Signal

Connecting the machine emergency stop

Figure 1-13 below illustrates the connection of the machine emergency stop to the power
supply module. You must supply the cable for this connection. Connectors are supplied with
the servo amplifier.
1. Locate the 3-pin connector identified by FANUC part # A02B-0120-K321.
2. Connect the machine emergency stop device across pins 2 and 3 of the connector
using a normally closed contact. Assemble the connector just like you see it in the
diagram below using a 16 gauge (1.25 mm2) wire.
3. Connect the wired connector into the slot labeled CX4 ESP on the face of the power
supply module.

Note
If a normally closed contact is not connected between pins 2 and 3 on
connector CX4 ESP, the amplifier will not energize the motor and an alarm
will be initiated. If no E-stop switch is used, you must make this connection
with a wire jumper.
Normally Closed
Machine E-STOP Device(s)

+24V

*ESP

CX4 ESP connector pin layout

Figure 1 - 13. Connecting the machine emergency stop signal

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Connecting the main power control signal

Main power to the servo drives is controlled by an external magnetic contactor (MCC) which
turns on to allow the motors to be driven. This connection enables this control signal.
1. Locate the 3-pin connector identified by FANUC part # A06B-6089-K201.
2. You must supply the cable for this connection. Connect the magnetic contactor coil
across pins 1 and 3 according to the Figure 1-14 below. You need to use a 16 gauge
(1.25 mm2) wire.
3. You will need a spark killer (voltage suppresser device) consisting of a resistor and
capacitor in series to protect the internal contacts in the power supply module. Table
1-4 below lists the recommended values for the spark killer.

MCC

MCCOFF3

Coil Spark killer

MCCOFF4
~

external power supply

(according to the coil voltage)

CX3 MCC connector pin layout

Figure 1 - 14. Connecting the main power control signal

Table 1 - 4. Recommended coil voltage, capacitance, and resistance for spark killer

Coil Voltage Capacitance Resistance

24V DC 0.22µF 22Ω

100V AC to 240V AC 0.1µF 220Ω

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Connecting the Control to the I/O Link

This section contains an example of a connection on the GE Fanuc I/O link. Since it would be
impossible to take a look at all of the possible setup combinations, we will concentrate on the
recommended GE Fanuc operator’s panel for i-series controls and the I/O Unit Model A.
Figure 1-15 below is the connection diagram for our example.
Even if this differs from your own setup, it might help to just browse through this section to see
how the connections are made. You will notice, for example, that connections on the I/O link
always go from connector JD1A on one module to connector JD1B on another. Please refer to
the 16i /18i / 160i / 180i - Model A Connection Manual or the 21i / 210i - Model A
Connection Manual for connection information not covered in this chapter.

operator’s Model
panel A I/O
JD1B it
JD1A CP32
CP1A
control
JD1B JD1A in from 24V DC
power supply

CE53

MPG JA3

MPG

MPG
machine
CE54 operator’s
panel
CPD1

CPD1
PL1

in from 24V DC
power supply

Figure 1 - 15. Connecting the GE Fanuc operator’s panel

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The GE Fanuc Operator’s Panel for i-series Controls

The GE Fanuc Operator’s Panel is identified by GE Fanuc, see Chapter 1 page 8. Follow these
steps to connect the operator’s panel (see Figure 1-15 on the previous page for a complete
connection diagram for the operator’s panel). Note that all of the supplied devices are wired
except for the emergency stop push-button. The emergency stop wiring will differ from
system to system and this must be done by the machine tool builder.
1. In order to connect the operator’s panel, you must first
physically mount the operator’s panel connection unit
onto the back of the operator’s panel.
2. If you carefully look at the connection board, it has five screw holes - three along one
edge and two along the other edge. This board can only be mounted onto the back of
the operator’s panel in one way. Remove the screws from the back of the operator’s
panel, line up the holes, and screw in to secure the board.
3. Now, in order to connect the operator’s panel connection unit
to the I/O link, locate the I/O link cable identified by GE Fanuc part :

Specification Length Remarks Application

LX660-2007-T010/L500R0 0.5 m

LX660-2007-T010/L1R003 1m

LX660-2007-T010/L2R003 2m

LX660-2007-T010/L3R003 3m Connector
A02B-0120-K302
LX660-2007-T010/L4R003 4m 2nd Connector Cell Controller – I/O unit

LX660-2007-T010/L5R003 5m A02B-0120-K302 JD1A – JD1B

Cable material
LX660-2007-T010/L6R003 6m LX66L-0002-0284
LX660-2007-T010/L7R003 7m

LX660-2007-T010/L8R003 8m

LX660-2007-T010/L10R03 10 m

LX660-2007-T013/L500R0 0.5 m

LX660-2007-T013/L1R003 1m

LX660-2007-T013/L2R003 2m
Connector
LX660-2007-T013/L3R003 3m A02B-0120-K302
2nd Connector
LX660-2007-T013/L4R004 4m A02B-0120-K302 Cell Controller – I/O unit

LX660-2007-T013/L5R003 5m Cable material JD1A – JD1B

LX66L-0002-0283
LX660-2007-T013/L6R003 6m Cable material with
PUR sheath
LX660-2007-T013/L7R003 7m

LX660-2007-T013/L8R003 8m

LX660-2007-T013/L10R03 10 m

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Insert one end of this cable into the connector labeled JD1A on the back of the control.
4. Insert the other end of the cable into the connector labeled JD1B on the operator’s
panel connection board.
5. Next, locate the two flat gray ribbon cables which have been provided for wiring the
operator’s panel to the operator’s panel I/O module. One end of each of these cables
has already been attached to the operator’s panel. Locate the cable with GE Fanuc
part # 44C742960 and snap it into the connector labeled CE53 on the operator’s panel
connection unit.
6. Find the cable with GE Fanuc part # 44C742961 and insert it into the connector
labeled CE54 on the operator’s panel connection board.

The Manual Pulse Generator (MPG)

The manual pulse generator is an optional item and must be purchased separately from the
operator’s panel. If your setup does not include an MPG, ignore this section.
It can be connected to the system as follows:
1. Locate the connector identified by part # A02B-0120-K303. This is the
connector which plugs the MPG into the operator’s panel I/O module. As you can see
from Figure 1-15 on page 1-21, up to three MPGs can be connected to the operator’s
panel I/O module.
2. See Figure 1-16 on the next page for the wiring of the MPG to the operator’s panel I/O
module. Use the connector pinout in Figure 1-17 to solder the correct signal wires to
the corresponding contacts.
3. When you’re done wiring the MPG, insert the 20-pin connector into the slot labeled
JA3 on the operator’s panel I/O module.

4. Now, in order to connect the operator’s panel connection unit to the I/O link, locate
the I/O link cable identified by GE Fanuc part :

Specification Length Remarks Application

LX660-8018-T001/L500R0 0.5 m

LX660-8018-T001/L1R003 1m

LX660-8018-T001/L2R003 2m

LX660-8018-T001/L3R003 3m
Connector
LX660-8018-T001/L4R003 4m A02B-0120-K301
And cable lugs For one MPG
LX660-8018-T001/L5R003 5m Cable material
LX66L-0002-0312
LX660-8018-T001/L6R003 6m

LX660-8018-T001/L7R003 7m

LX660-8018-T001/L8R003 8m

LX660-8018-T001/L10R03 10 m

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Specification Length Remarks Application

LX660-8018-T011/L500R0 0.5 m

LX660-8018-T011/L1R003 1m

LX660-8018-T011/L2R003 2m

LX660-8018-T011/L3R003 3m
Connector
LX660-8018-T011/L4R003 4m A02B-0120-K301
And cable lugs For 3 MPG
LX660-8018-T011/L5R003 5m Cable material
LX66L-0002-0312
LX660-8018-T011/L6R003 6m

LX660-8018-T011/L7R003 7m

LX660-8018-T011/L8R003 8m

LX660-8018-T011/L10R03 10 m

Manual pulse
Signals Pin numbers Terminal block generators
#1
1 5 HA2
HA2 HA2
2 6 HB2
HB2 HB2
9 3 +5V
+5V +5V
12 4 0V
0V 0V
#2
3 5
HA2 HA2 HA2
4 6
HB2 HB2 HB2
18 3
+5V +5V +5V
14 4
0V 0V 0V
#3
HA2 5 HA2 5
HA2
HB2 6 HB2 6
HB2
+5V 20 +5V 3
+5V
0V 16 0V 4
0V
Shield

Ground plate
Cable Wire

Figure 1 - 16. Manual pulse generator connection

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 1

connector side view

soldering side view
(front)
(back)

20 18 16 14 12
10 9 8 7 6 5 4 3 2
1

10 8 6 4 2
20 18 16 14 12

9 7 5 3
1

Figure 1 - 17. Pin layout on the MPG connector

I/O Unit Model A

Follow these steps to connect the I/O Unit Model A to your GE Fanuc operator’s panel.
1. Two I/O link connectors are supplied when you order the GE Fanuc operator’s panel.
They are identified by FANUC part # A02B-0120-K301, and you can use these to
make this connection yourself. However, if you choose to do this, you must supply the
cable.
2. If you have ordered the I/O link connection cables, you won’t need the connectors.
The cables will have one of the following GE Fanuc part numbers depending on its
length, see also Chapter 1 page 29.
Locate the cable you will be using for this connection.
3. Attach one end of this cable to connector JD1A on the operator’s panel I/O module.
4. Attach the other end of the cable to connector JD1B on the I/O Unit Model A interface
module (see Figure 1-6 for location of connectors).
5. Up to 1024 inputs and 1024 outputs can be assembled using Model A I/O. These I/O
modules may be “daisy chained”, by using a cable to connect JD1A from one module
to JD1B on the next module. The cable options for this connection are listed in step 2.

Connecting 24V DC Power to I/O Unit Model A

Follow these steps to connect 24V DC power to the Model A I/O modules. You must provide
the power supply. When selecting the power supply, please refer to Chapter 5 in the I/O Unit
Model A Connection/Maintenance Manual (publication no. B-61813E) to determine the
current requirements of each I/O module.
1. Locate the brown connector which connects the power to the I/O modules. It is
identified by FANUC part # A02B-0072-K893.
You must provide an 18 gauge (0.75 mm2) for this connection.

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 1

2. This connection consists of two lines. Connect the +24V line to pin 1 of the
connector. Connect the 0V line to pin 2 of the connector.
3. When you have completed wiring the connector, insert it into the slot labeled CP32 on
the face of the I/O module.
4. On the other end, connect the +24V line (pin 1) to the positive terminal at the power
source and the line labeled 0V (pin 2) to the common of the power source.

Note
Even though the control and operator’s panel connection unit also require
24V DC power, we recommend that you use a separate power supply just for
the I/O modules. There are strict timing requirements which define how the
control and I/O modules have to be powered on and off. In order to prevent
CNC errors, you should use a relay to connect the switching device on the
operator’s panel to the I/O power supply.

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Connecting 24V DC Power to the Control & Operator’s Panel

Since the i-series controls do not have built-in power switching capabilities, the new GE Fanuc
operator’s panel for i-series is equipped with ON/OFF push-buttons for easy power switching.
In order to take advantage of this feature, we recommend that you wire the 24V DC power
according to the diagram below.
As mentioned in the beginning of the chapter, you must supply the regulated 24V DC power
source (24V ± 10% which includes ripple and noise) for the control and operator’s panel
connection unit. When selecting the power supply, keep in mind the following things:
1. The switching device on the operator’ s panel is rated at
a maximum of 8 amps.
2. The incandescent bulbs which light up each push-button on the operator’s panel draw
40mA of current each.
3. The current requirements for each control will depend on the hardware options you
choose for your control (if any). Refer to the appropriate manual to calculate the
current requirements of your control:

Section 3.3 in the 16i / 18i / 160i / 180i - Model A Connection Manual
Section 3.2 in the 21i / 210i - Model A Connection Manual

insert into CP1A on

control unit

0V

+24V

CPD1

+24V
operator’s panel
0V connection unit

PD1 printed circuit board on back of operator’s panel

1 2 3 4 operator’s panel

24V DC
power supply

positive terminal +24V

common 0V

Figure 1 - 18. 24V DC power connections between the operator’s panel connection unit and
control

B-63003EN-2/01 Chapter 1 Assembling the 16i/18i/21i 1 - 35

 1

In order to connect the 24V DC power to your control and operator’s panel connection unit,
follow these steps:

1. Locate the green four-pin connector which is inserted in

connector PD1 on the printed circuit board on the back of
the operator’ s panel. Go ahead and pull this out. Note
that the pins are numbered from 1 to 4 from left to right
when you are looking at the operator’s panel from the
back (see Figure 1-18 on previous page).
2. You must supply an 18 gauge (0.75 mm2) wire for this connection. This connection
consists of two lines. Connect the +24V line to the positive terminal of the power
supply. Connect the 0V line to the common on the power supply.
3. On the other end, connect the +24V line to pin 1 on the green four-pin connector.
Connect the 0V line to pin 2 of this connector.
4. Now, locate one of the black 3-pin connectors identified as FANUC part # A02B-
0120-K324. There are two shipped with the operator’s panel. Again, you have to
supply an 18 gauge (0.75 mm2) wire for this connection. On the green connector side,
connect the +24V line to pin 4 and the 0V line to pin 3.
5. On the black 3-pin connector side of this cable, connect the +24V line to pin 1 and the
0V line to pin 2.
6. Insert the wired green connector back into the slot labeled PD1 where you took it out
of.
7. Insert the 3-pin connector into the connector labeled CPD1 on the operator’s panel
connection unit. CPD1 has two slots. It doesn’t matter which one you plug the
connector into.
8. For the next connection, the wiring is identical on both sides of the cable. The two 3-
pin connectors are identified by FANUC part # A02B-0120-K324. One connector is
shipped with the control. The other is the second one provided with the operator’s
panel. You must provide an 18 gauge (0.75 mm2) wire for this connection.
9. On both sides of the cable, connect the +24V line to pin 1 of the black connector.
Connect the 0V line to pin 2 of the connector.
10. Insert on end of the wired 3-pin connector into the second CPD1 slot on the operator’s
panel connection unit.
11. Plug the other end connector on this cable into the slot labeled CP1A on the back of
the 16i/18i/21i control.

Warning
You MUST make sure that you correctly wire the power source to the
control. If you reverse the polarity of the power to the control, you will
blow the back light on the LCD. Confirm that the correct wire is
connected to the correct pin before applying power!

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 1

Grounding the 16i/18i/21i Machine Tool Control System

The control system must be properly grounded. The following three ground systems are
provided for the CNC machine tool (see Figure 1-19 below):
1. The signal ground system supplies the reference voltage (0V) of the electrical signal
system.
2. The frame ground system is used for safety and suppressing electrical noise. In this
system, the frames, cases of the units, panels, and shields for the interface cables
between the units are connected.
3. The system ground system is used to connect all of the separate frame ground systems
to a common ground.

Machine
Power Servo amp control tool
24V DC magnetics
power unit

Operator’s
panel

Distribution board

Signal grounding system

Frame grounding system
System grounding system

Figure 1 - 19. Block diagram of proper grounding

Keep the following things in mind when connecting the ground systems:
• Connect the signal ground to the frame ground at only one place in the CNC control
unit.
• The resistance of the system ground must be 100 ohms or less (class 3 grounding).
• The system ground cable must have enough cross-sectional area to safely carry the
fault current into the system ground when an accident occurs. Typically, it must have
the cross sectional area of the AC power cable or more.
• For the operator’s panel and the machine, use the ground wire in the AC power cord.

B-63003EN-2/01 Chapter 1 Assembling the 16i/18i/21i 1 - 37

 Chapter Configuring the 16i/18i/21i
2

The GE Fanuc i-series CNC is a high-performance control with an extensive set of features and
can be adapted to many different lathe and machining center applications. You can easily make
adjustments to alter or improve your system using data registers in the control.
These data registers are called parameters.

Although the control contains several hundred parameters, only a small number of these must
be set for most applications. This chapter explains how to set these basic parameters so that
you can get the motor up and running.

For parameter information not contained in this chapter, please refer to the appropriate manual
(s):

16i/18i/160i/180i - Model A Parameter Manual (publication no. B-63010EN)

21i/210i - Model A Parameter Manual (publication no. B-63090EN)
α Series AC Servo Motor Parameter Manual (publication no. B-65150E)

B-63003EN-2/01 2-1
 2

Section 1 Setting the Initial Parameters

Once you have confirmed that the supplied cables have been attached to the appropriate
connectors, you can go ahead and power up the control by pushing the ON button on the
operator’s panel. When the control comes up, you will see a list of alarm messages displayed in
a rectangle on the right hand side of the LCD. Ignore these for now.

After a brief overview of parameters and how to enter their values, you will begin by just
setting the most basic parameters as well as those necessary to eliminate the alarms.
Once you have successfully gone through the Startup Guide and turned the motors, you can
go back and enter the parameters specific to your application.

Types of Parameters
There are two types of parameters for the control:

1. Bit-type parameters - These are basically ON/OFF switches which enable or disable
a certain function. They can only be given the binary values 0 and 1.
Ex.
0000 SEQ INI ISO TVC
0 0 0 0 0 1 0 0

parameter #
bit #7 • • • • • • bit #0
Bit-type parameters will be illustrated in this way throughout this manual. The text
above certain bits represents the three character name designated to that certain
parameter. In this example, parameter 0000.2 (the value after the decimal is the bit #)
has the value 1.
2. Word-type parameters - These are used for parameters requiring a numerical value.
Ex.
1410 DRY RUN RATE 5000

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Entering Parameter Values from the MDI Panel

First, let’s briefly go over the notation used in this manual. Hard keys are those keys which are
located on the MDI panel. They will be designated by square brackets [ ]. Soft keys,
meanwhile, are located in a single row directly beneath the LCD. They will be designated by
parentheses ( ).

In order to set parameter values after initial power-up, use the following procedure:

1. Press [SYSTEM]. The alarm messages should be replaced by

the parameter screen.
2. If the parameter screen does not appear, press (PARAM) and it will appear.
3. For a bit-type parameter, cursor over to the bit you would like to set using the [←],
[→], [↑], and [↓] hard keys. Then press [1] followed by [INPUT].
4. For a word-type parameter, simply enter the numerical value using the MDI panel and
then press [INPUT].
To display the specific parameter which you are looking for on your screen, you can do one of
two things:
1. Enter the parameter number from the MDI panel. This will give you a (NO. SRH) soft
key option. Press this and the display should show the specified parameter.
2. Use the [PAGE ↑] and [PAGE ↓] keys to scroll to the parameter you are searching for.
However, if the parameters are numerically far apart, this can tend to be cumbersome.

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Parameter Write Enable (PWE)

Before you can begin entering any parameter values, you must turn on the Parameter Write
Enable(PWE) bit. PWE is the built-in software write protect feature which prevents any
accidental changes to you parameter values once they have been set.

In order to turn on PWE, enter the following keystrokes:

1. Press the [OFFSET SETTING] hard key.

2. Press the (SETING) soft key option. This will bring you to the handy setting screen
(see Figure 2-1 below).

SETTING (HANDY)

0 (0 : DISABLE 1 :
PARAMETER WRITE =
ENABLE)
TV CHECK = 0 (0 : OFF 1 : ON)
PUNCH CODE = 0 (0 : EIA 1 : ISO)
INPUT UNIT = 0 (0 : MM 1 : INCH)
I/O CHANNEL = 0 (0-3 : CHANNEL NO.)
SEQUENCE NO. = 0 (0 : OFF 1 : ON)
0 (0 : NO CNV 1 :
TAPE FORMAT =
F10/11)
SEQUENCE STOP = 0(PROGRAM NO.)
SEQUENCE STOP = 0(SEQUENCE NO.)

CONTRAST ( + = [ ON : 1 ] - = [ OFF : 0 ])

Figure 2 - 1. Handy setting screen

3. The cursor should already be on the PWE bit. From the MDI panel, press [1] followed
by [INPUT] to turn on PWE. You will see that the following alarm message appears on
your screen:

100 PARAMETER WRITE ENABLE

This alarm will appear every time you power up the control until you go back and turn
off the bit. However, since you still need to set some other parameters, you can ignore
it for now and use the [RESET] + [CAN] keys to remove the alarm after each power-up.
Both keys must be pressed at the same time.

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 2

Removing the Alarms

Now that we know how to set parameters, we can enter values for only the most important ones
and those needed to remove the alarms. Using the procedure described above, set the following
parameters beginning on the next page. For detailed information on each parameter, please
refer to the GE Fanuc 16i/18i/160i/180i - Model A Parameter Manual or 21i/210i - Model A
Parameter Manual.

Note
Keep in mind that each setup might have different parameter settings for the
number of axes and names of axes. The examples contained in this section
will refer to a 21i-T configured to control three axes.

Parameters of Setting
Please set the parameters as shown below. The parameters in this grouping will be identical for
all controls.

Set ISO to 1 to select ISO code as method of data output. Set INI to 0 to choose millimeters as
your unit of input. Throughout this manual, we will use millimeters for all examples
involving measurement units. Leave INI set to 0 if you would like to use mm as your unit of
input.

0000 SEQ INI ISO TVC

0 0 0 0 0 0 1 0

Number of Axes
Specify the number of axes controlled by the CNC.

1010 CNC CONTROL AXIS 3

Now, you will notice that the alarm messages screen popped back up with a new alarm:

000 PLEASE TURN OFF POWER

Some parameters will require you to cycle the power (turn it off and then back on) before they
take effect. Since we still need to set quite a few parameters, simply ignore it and just cycle the
power once when you have set all of the basic parameters. To get back to the parameter screen,
press [SYSTEM] followed by (PARAM).

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 2

Axis Names
Defines the axis letters referenced in the motion program. Replace the default values with the
desired letter name for each axis using the following conversions.

65 = A 85 = U 88 = X
66 = B 86 = V 89 = Y
67 = C 87 = W 90 = Z

1020 AXIS NAME 1 88

2 90
3 67

Reference Position Return Not Required

Set ZRN for each axis. This prevents an alarm when a command is generated in automatic
operation before a reference is performed.

1005 RMB MCC EDM EDP DLZ ZRN

X 0 0 0 0 0 0 0 1
Z 0 0 0 0 0 0 0 1
C 0 0 0 0 0 0 0 1

Inch or Metric Feedback

You don’t need to set this parameter to remove any alarms, but we will be referring to
something called the least command increment (LCI) later in the chapter. This is the smallest
axis movement the machine can command and this parameter tells the control what
measurement system to use. If you have a metric system machine, leave INM at zero. If you
have an inch machine, set INM to one.

1001 INM
0 0 0 0 0 0 0 0

This next parameter sets the actual value of the LCI. The common setting used in most
applications is 0.001mm or 0.0001 inches, depending on the measurement system you are
using. Leave ISC and ISA set to zero to use this standard setting for your least command
increment.

1004 IPR ISC ISA

0 0 0 0 0 0 0 0

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 2

Servo Axis Number

Enter the value -128 for each individual axis. This suppresses servo alarms when the control is
run without servo amplifiers and motors hooked up.

1023 SERVO AXIS NUM. X -128

Z -128
C -128

Positive Stroke Check

For all axes, set the parameter value to -1. This parameter must be set to less than the value set
for the negative stroke check (parameter 1321). Since parameter 1321 is set to zero at power-
up, setting this parameter to -1 causes the control to ignore all software overtravel limits.

1320 LIMIT 1+ X -1
Z -1
C -1

Feedrates
For the following four feedrate parameters, enter the values shown in the examples. Where
multiple axes apply, enter the same value for each separate axis.

1410 DRY RUN RATE 5000

1420 RAPID FEEDRATE X 6000

Z 6000
C 6000

1422 MAX CUT FEEDRATE 5000

1423 JOG FEEDRATE X 4000

Z 4000
C 4000

Acceleration/Deceleration Jog Time Constant

Set this parameter to a positive value in order to prevent servo alarm 410 AXIS EXCESS
ERROR

1624 JOG TIME CONST X 20

Z 20
C 20

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 2

CVR
Set CVR to prevent servo alarm 404 VRDY ON.

1800 TRC RBK FFR OZR CVR

0 0 0 0 0 0 1 0

Servo Gain
Set the servo loop gain for each axis to 3000. This is the standard setting.

1825 SERVO LOOP GAIN X 3000

Z 3000
C 3000

Positioning Deviation Limit - Moving State

Set this to a high value to prevent servo alarm 411 AXIS EXCESS ERROR.

1828 ERR LIMIT : MOVE X 10000

Z 10000
C 10000

Positioning Deviation Limit - Stopped State

Set this to a low, non-zero value to prevent servo alarm 410 AXIS EXCESS ERROR.

1829 ERR LIMIT : STOP X 20

Z 20
C 20

Interlocks
Set ITL, ITX, and DIT to disable all axis interlocks.

3003 MVG MVX DEC DIT ITX ITL

0 0 0 0 1 1 0 1

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 2

Hardware Overtravel
Set OTH to have hardware overtravels ignored.

3004 OTH
0 0 1 0 0 0 0 0

Servo Setting Screen Enable

Set this bit to enable the servo setting screen. We will be using the servo setting screen to set
important servo parameters.

3111 NPA OPS OPM SVP SPS SVS

0 0 0 0 0 0 0 1

ISI
Set this bit to disable serial spindle alarms.

3701 SS2 ISI

0 0 0 0 0 0 1 0

Cycle Power
You have now set all of the parameters necessary to remove most of the alarms. Please turn the
power off and then back on again to restart the control. You will see that there is still one alarm
message on your screen:

100 PARAMETER WRITE ENABLE

As mentioned before, press the hard key combination [RESET] + [CAN] to eliminate this alarm.

Let’s move on now to servo parameters . . .

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 2

Section 2 The Servo Setting Screen

The servo setting screen is a grouping of the most important servo parameters conveniently
located on a single display. It offers a way to enter these servo parameter values without having
to search for and set each individual parameter as we did in the previous section.

In order to get to the servo setting screen, enter the following keystrokes:

1. Press [SYSTEM].
2. Press the (+) soft key. This is the rightmost soft key under the LCD.
3. Press (SV-PRM). The servo setting screen should appear.
4. If it did not appear, press (SV. SET) now and it will appear.

On the right hand side of your LCD, you should see the something like this:

SERVO SETTING

X-AXIS Z AXIS
INITIAL SET BITS 00001000 00001000
MOTOR ID NO. 0 0
AMR 00000000 00000000
CMR 2 2
FEEDGEAR N 0 0
(N/M) M 0 0
DIRECTION SET 0 0
VELOCITY PULSE NO. 0 0
POSITION PULSE NO. 0 0
REF. COUNTER 0 0

Figure 2 - 2. Servo setting screen

As you can see, there are two axes displayed at a time. Using the [PAGE ↑] and [PAGE ↓] keys
as well as the [↑], [↓], [←], and [→] cursors, you can move around the servo setting screen to get
to any parameter.

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 2

Determining the Motor ID Number

For proper setup, the control needs information that is provided by the model number of each
motor. The motor model number is located on a tag affixed to the motor and should look like
this:

A06B-xxxx-Byzz
these four digits determine the motor ID

To find the correct value for the parameter labeled MOTOR ID NO., simply match the motor
identifier which you read off the motor tag to the motor type in the right column. Enter this
number on the servo setting screen as your MOTOR ID NO parameter. Do this for each axis.

Let’s say for example that your motor is labeled A06B-0121-B072. Looking up 0121 in the
table, we can determine the motor type to be 7.

Once again, the alarm messages screen pops up with an alarm:

000 PLEASE TURN OFF POWER

To get back to the parameter screen, press [SYSTEM] followed by (PARAM).

Table 2 - 1. Motor Type Definition

xxxx Motor xxxx Motor xxxx Motor

Type Type Type
0013 13 0152 22 0186 107
0101 35 0153 23 0331 39
0102 36 0157 30 0332 40
0105 33 0158 29 0333 41
0106 34 0161 24 0371 61
0113 13 0162 25 0372 46
0121 7 0163 26 0374 84
0123 15 0165 100 0376 97
0126 8 0166 101 0377 98
0127 16 0169 108 0410 90
0128 17 0171 1 0411 91
0141 9 0172 2 0412 92
0142 18 0176 3 0413 93
0143 19 0177 4 0561 56 or 68
0145 10 0178 5 0562 57 or 69
0146 27 0182 104 0564 58 or 70
0147 20 0183 105 0571 59
0148 21 0185 106 0572 60
0151 28

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 2

Setting CMR and the Flex Feed Gear

Before we set the values for CMR and the flex feed gear, we will take a look at what exactly
they do.

DETECT
UNITS

Command
Pulse
Interpolator CMR
Motor

DETECT UNITS

N REFERENCE
M COUNTER

Feedback Pulse Encoder

Figure 2 - 3. Semi-closed servo control loop block diagram

First of all, the diagram above represents a semi-closed loop system. That just means that we
are using the built-in motor encoder instead of a separate feedback device. A separate feedback
device slightly complicates the CMR and N M calculations, but the principles behind the servo
control loop are the same in either case.

The interpolator inside the CNC generates command pulses which tell the motor to turn a
certain distance. While the motor is turning, the resulting axis movement is communicated
back to the CNC by the encoder in the form of feedback pulses.

This is where CMR and N M come into play. They are unitless multipliers which you can use
scale the command pulses and feedback pulses to a common unit. Basically, they just serve as
software gearboxes. What we want to do is make the command pulses per distance commanded
equal the feedback pulses per distance moved.

So, what does this mean and how you do this?? Let’s look at how we can calculate these values
by going through an example.

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 2

The Equation
CMR and N M are calculated according to the following equation:

number of command pulses number of feedback pulses N

× CMR = Pulse Count = × eq. 1
distance commanded distance moved M

This equation might seem intimidating at first, but if we look at it carefully, it can be broken
down and easily understood.

To make things clearer, let’s say that we are working with millimeters (instead of inches or
degrees). This is set by parameter 1000 bit #0. The left side of the equation represents the
pulses
which are entering the big black dot in Figure 2-3 from the positive side. The right side
mm
pulses
of the equation then, represents which are entering from the negative side.
mm

pulses
The goal of this calculation is to use CMR and N M to make the number of entering the
mm
black dot equal on both sides.

The Left Side

If we ignore the right hand side of the equation for now, we have this remaining:

number of command pulses

× CMR = Pulse Count eq. 2
distance commanded

The first thing we can do is figure out the pulse count. The pulse count is what we referred to
pulses
above as the entering the black dot. Now, there is a value which the customer must
mm
specify known as the detection unit. This value determines “this is how much precision I need
for my control” and it represents the smallest movement the CNC can detect. Since this value
mm
is specified in units of , all we have to do is flip this number to get the pulse count.
pulse

Already then, we have one given out of the three quantities in this equation.

Next, let’s look at what “number of command pulses per distance commanded” is. There is a
parameter (1004 bits #0 & #1) known as the least command increment (LCI) which the
customer must also specify. This is the smallest unit of movement the CNC can command and
mm
it has units of . Just like we did above, if we flip the LCI over as well, we have the
pulse

quantity we are looking for.

You can see then, that in order to calculate the value for CMR, you need to find the LCI and
detection unit specified by the customer and just flip them over. The rest is just taking eq. 2
and plugging and chugging.

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 2

The Right Side

We’ll concentrate on the right side of the equation now. The right side of the equation looks
like this:

number of feedback pulses N

Pulse Count = × eq. 3
distance moved M

The fraction N M in the equation is also known as the flex feed gear. The flex feed gear is the
scaling factor on the right side of the equation just like CMR was on the left side. Since we
already figured out the pulse count when we solved for CMR, if we figure out how to calculate
the “number of feedback pulses per distance moved”, we’ll have the flex feed gear as well.

The first thing we have to do here is find out what kind of feedback you have and its resolution.
When using motor feedback, you have to check the motor number to find out which encoder it
has built-in. You can find this information in Chapter 2, Section 2 of the GE Fanuc Servo
Description Manual (publication no. B-65002E). This will give you a quantity with units of
pulses
; that is, how many pulses of feedback per revolution of the motor.
revolution

revolutions
The next thing you need to do is to come up with a value measured in units of . You
mm
pulses
can see then, that you can multiply the two values and cancel units to get which we are
mm
revolutions
looking for. The method to calculate will vary from setup to setup. It will depend
mm
upon things such as screw pitches and gearbox ratios, and if you are using separate feedback,
other coupling factors will have to be taken into consideration as well. The easiest way to
approach this calculation is to find out the mechanics of the system and line up the units so that
revolutions
they cancel to give .
mm

pulses
Once you have that value, you can multiply it with your motor resolution to get . The
mm
rest involves just taking the values you have and plugging them into eq. 3 to calculate N M .

This is all illustrated in the following example.

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Example - Determining Settings for a Semi-Closed Feedback Loop

Figure 2-4 illustrates how a motor could be connected to the screw. We have a 1,000,000 count
built-in encoder, a 10mm screw pitch, and a 2:1 gearbox.

10mm screw pitch

1,000,000 pulses/rev
200 teeth

100 teeth
} 2:1 gearbox

Figure 2 - 4. Diagram of the setup used in this example

Procedure for Calculating CMR and N M

1. Look up the detection unit and flip it over to get the pulse count.
2. Look up the LCI and flip it over.
3. Plug the previous two values into eq. 2 and calculate CMR.
4. Determine what kind of feedback you have and its resolution.
5. Find out the mechanics of the system ! gear ratios, screw pitches, etc.
6. Use the system mechanics to calculate revolutions mm .
7. Multiply the result from step 6 with the motor resolution from step 4.
8. Plug in values from steps 1 and 7 into eq. 3 to calculate N M

B-63003EN-2/01 Chapter 2 Configuring the 16i/18i/21i 2 - 15

 2

1. Look up the detection unit and flip it over to get the pulse count.
Let’s say that the customer specifies a detection unit of 0.05µm per pulse.

0.00005 mm 1 pulse 20,000 pulses

Flipping over , we have = .
pulse 0.00005 mm mm

2. Look up the LCI and flip it over.

The customer specifies a least command increment of 0.1µm per pulse.

0.0001 mm 1 pulse 10,000 pulses

Flipping over , we have = .
pulse 0.0001 mm mm

3. Plug the previous two values into eq. 2 and calculate CMR.
Plug in the values:

10,000 pulses 20,000 pulses

× CMR =
mm mm

Solving for CMR, we have CMR = 2.

Note
When you have determined the value of CMR, you must multiply it by 2 before
entering it into the servo setting screen. In this case, since we calculated our CMR to
be 2, we would have to enter the value “4” as the parameter.

4. Determine what kind of feedback you have and its resolution.

You can look for the motor number on the motor tag which is affixed to each GE
Fanuc motor.

Let’s say you read off the part number A06B-0313-B072#7000 from the motor tag.
Looking this up in Chapter 2, Section 2 of the Servo Description Manual, you could
1,000,000 pulses
determine that the pulse coder’s resolution is .
revolution

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5. Find out the mechanics of the system ! gear ratios, screw pitches, etc.

You will need to get this information from the machine tool’s specifications. It should
not be determined by trial and error.

Let’s say that we have the motor coupled to the screw via a 2:1 gearbox and the pitch
of the screw is 10mm. Rewrite this using units! This means that we have:

2 revolutions of the motor 1 turn of the screw

and
1 turn of the screw 1 mm of axis movement

6. Use the system mechanics to calculate revolutions

mm
.
We need to multiply the units now and line them up so that they cancel to give us
revolutions .
mm

2 motor revs 1 turn of screw 2 revolutions

× =
1 turn of screw 10 mm 10 mm

In our system, the axis moves 5mm for every motor revolution.

7. Multiply the result from step 6 with the motor resolution from step 4.
Multiplying the values, we have:

1 revolution 1,000,000 pulses 200,000 pulses

× =
5 mm revolution mm

8. Plug in values from steps 1 and 7 into eq. 3 to calculate N M

Plugging into eq. 3 yields:

20,000 pulses 200,000 pulses N

= ×
mm mm M

Solving for the unknowns, we have then, N = 1 and M = 10. These are the values you
would enter into the servo setting screen.

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Other Parameters on the Servo Setting Screen

We will continue now to set the remaining parameters on the servo setting screen. Here is a
brief description of each parameter and how to set them:

Initial Set Bits

Bit #1 in this sequence (the second bit from the right) must be set to zero for each axis before
cycling power. Upon power-up, this tells the CNC to look at the MOTOR ID NO. which you just
entered and to copy all parameters for that specific motor from the servo ROM into memory.
The control will automatically set bit #1 and bit #3 to one after initialization.

For most applications, you can just go ahead and set all eight bits to zero (it’s much easier to
remember). However, there may be instances where you would want to scale back the number
of feedback pulses by setting bit # 0 to one. If you need to do this, please refer to Chapter 2 in
the GE Fanuc α Series Servo Motor Parameter Manual (publication no. B-65150E) for more
information.

Direction Set
This parameter specifies the direction in which the motor rotates. It can only take on the
following two values:

111 clockwise as viewed from the pulse coder

-111 counterclockwise as viewed from the pulse coder

Ex. Set all three axes to clockwise rotation. Enter 111 for all three axes on the servo
setting screen next to DIRECTION SET.

Velocity Pulse No.

For most applications, set this parameter to 8192. If you have a situation where you need to set
bit #0 of the INITIAL SET BITS to one, you should enter the value 819. Again, please refer to
Chapter 2 in the GE Fanuc α Series Servo Motor Parameter Manual for more information.

Position Pulse No.

This parameter should be set to 12500 if you are using the built-in motor encoder. If you are
using separate feedback, please refer to Chapter 2 in the GE Fanuc α Series Servo Motor
Parameter Manual for the correct parameter setting.

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 2

Ref. Counter
This quantity is defined as the number of detection units per revolution of the motor. That
probably gets to be confusing, so here is an easier way to consider this value. The reference
counter is the actual pulse resolution of the motor scaled down by the factor N M calculated
previously. Continuing with the example in this section, we can calculate the reference counter
as follows:

1,000,000 feedback pulses 1

× = 50,000 pulses per revolution
1 motor revolution 20

On the servo setting screen, you would enter 50,000 as the parameter value for REF. COUNTER.

Putting It Together
If we enter parameters into the servo setting screen using values we obtained in the examples
above, it should look like the screen below. For simplicity’s sake, identical values have been
used for both the X and Z axes. Keep in mind, however, that you must follow the servo
parameter setting procedure for each axis separately.

Please turn off the power to the control before moving on to the next chapter.

SERVO SETTING

X-AXIS Z AXIS
INITIAL SET BITS 00000000 00000000
MOTOR ID NO. 7 7
AMR 00000000 00000000
CMR 20 20
FEEDGEAR N 1 1
(N/M) M 2 2
DIRECTION SET 111 111
VELOCITY PULSE NO. 8192 8192
POSITION PULSE NO. 12500 12500
REF. COUNTER 50000 50000

Figure 2 - 5. Servo setting screen complete with parameters

Remember to power down the control before moving on!

B-63003EN-2/01 Chapter 2 Configuring the 16i/18i/21i 2 - 19

 Chapter
Installing the Startup Ladder
3
By now, you should have connected the control to the entire machine tool control system and set the
basic parameters. However, you still need a ladder . . .
This chapter outlines the steps necessary to load the startup ladder onto your control.

Caution
Please remember that this ladder was provided only as a developmental tool to
help you get the motors running. It is by no means a completely “functional”
ladder. However, it will give you a starting point from which you can then
customize it to suit your machine’s specific application.

Before loading the ladder, please take note of the following items:
• We have provided the ladder files to you on a 3 ½” floppy disk. In order to load a ladder
onto your control, you will need an SRAM card and a PC with a PCMCIA card drive. The
file must be copied onto the SRAM card before it can be used on the control.

GE Fanuc offers the following two SRAM cards:

A87L-0001-0150/2M 2 Megabyte
A87L-0001-0150/4M 4 Megabyte

Note: Lithium battery type CR2025 or similar is required

• If you have chosen to provide your own operator’s panel, you will have to develop the entire
ladder yourself. Being that this is a startup guide, this chapter does not include a discussion
on ladder editing. If you would like more information on the specifics of ladder language
programming, please refer to the GE Fanuc PMC Model
PA1/PA3/RA1/RA2/RA3/RB/RB2/RB3/RB4/RB5/RB6/RC/RC3/RC4/NB/NB2 Ladder
Language Programming Manual (publication no. B-61863E).

B-63003EN-2/01 3-1
 3

Section 1 Overview

Before loading the ladder, here is a quick summary of machine control and the purpose of the ladder.
If you are already familiar with this, feel free to skip ahead to the next section.

Machine Control
The 16i/18i/21i machine tool control system consists of the control, motor(s), servo amplifiers, I/O,
and a machine tool and its operator interface (see Figure 3-1 below). The control unit itself is
comprised of two parts: the motion control and the machine control:
1. The motion control is responsible for generating motion commands signals and interpreting
the feedback signals as described in the previous chapter. This is known as the computer
numerical control (CNC). In addition, it provides the link between you and the control via
the LCD and MDI units. The CNC communicates with the other part of the 16i/18i/21i, the
machine control.
2. The machine control is a programmable logic controller (PLC) embedded within the
16i/18i/21i. It is referred to as a programmable machine control (PMC) within the
16i/18i/21i and it supports the interface between the CNC and the machine. For example,
the switches, buttons, and lights (start, stop, etc.) used to run or support the machine are all
managed by the machine control.

Machine Machine
I/O
Control
(PMC)
Machine
Operator
Panel

LCD
Servo
MDI Motion Amplifier
Control
(CNC)

16i/18i/21i

Figure 3 - 1. 16i /18i / 21i machine tool control system block diagram

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 3

The Ladder Diagram

If you look at Figure 3-1 on the previous page again, you will notice that the CNC cannot “talk”
directly with the machine tool. They must communicate to each other through the PMC. For
example, if a VALVE PRESSURE LOW signal were generated by the machine, the PMC must relay
this information to the CNC. How does the PMC do this?
The PMC must be programmed to “know” how to tell the CNC that the valve pressure has dropped.
This program is called the sequence program and the ladder diagram is just a visual representation of
this. As you can see in Figure 3-2 below, each relay contact symbol in the ladder diagram
corresponds to a PMC instruction in the sequence programming memory.
The processor in the PMC “sweeps” through the ladder at periodic intervals. This interval depends
upon the number of instructions the CPU must perform (i.e. the number of rungs in the ladder), but it
is typically 8ms or 16ms. That means that the PMC is being updated every 8ms with new information
from both the CNC and the machine tool.

PMC (Programmable Machine Controller)

relay contact symbol corresponding PMC

instruction

CPU

Sequence programming
Ladder diagram memory

RD X0.0
AND R10.1
OR X6.1
X0.0 R10.1 R20.3 Y0.0 AND.NOT R20.3
WRT Y0.0

X6.1

Figure 3 - 2. Execution of sequence program by PMC

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 3

PMC Addresses
Understanding PMC addressing is very important in grasping how the PMC interfaces with the both
the CNC and the machine tool.

G address X address

CNC PMC Machine

Tool
F address Y address

Figure 3 - 3. Diagram of how addresses are related to each other

If you look at this diagram carefully, it is just simplified version of Figure 3-1. However, it makes
one important point which we have already talked about very clear. The CNC cannot “talk” directly
with the machine tool. They must communicate to each other through the PMC.
If the machine tool generated an alarm such as a VALVE PRESSURE LOW signal, it would have to
send a signal to an X address. An address is nothing more than a bit in an 8-bit PMC register. The
PMC would then have to recognize the change in the state of the X bit and output a signal to the CNC
using a G address. Likewise, if the CNC had to respond to this alarm, we would be talking about F
and Y addresses.
Table 3-1 below summarizes the types of PMC addresses:

Table 3 - 1. Description of different kinds of addresses

Symbol Kind of Signal

X Signal from machine to PMC
Y Signal from PMC to machine
F Input signal from CNC to PMC
G Input signal from PMC to CNC
R Internal relay

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 3

PMC Instructions
There are two types of PMC instructions which can be used to program your ladder logic.

Basic Instructions
There are 14 basic PMC instructions which the processor can be programmed to execute. They
include reading from and writing to addresses, boolean functions (AND, OR, NOT), and stack
register operations (shift left, shift right). The CPU has a 9-bit operation stack register which it uses
to store intermediate results of logical operations while running the sequence program.
In the example from Figure 3-2, there are five relay contact symbols and five corresponding PMC
instructions. The CPU would execute the sequence program as follows:
1. Read in the signal of address X0.0.
2. Read in the status of address R10.1 and perform logical AND
with X0.0.
3. Read in X6.1 and logically OR it with the previous result.
4. Read in R20.3, invert the signal, and perform logical AND
with previous result.
5. Write the result out to address Y0.0

Functional Instructions
It would be very hard to write a sequence program using just the basic instructions mentioned above.
Some functions, such as the function for controlling the rotation via the shorter path, would be
extremely time-consuming to program.
Therefore, GE Fanuc provides a comprehensive library of functional instructions in addition to the 14
one-bit logical operations. Functional instructions including timers, counters, and decoders are made
available to programmers, allowing them to develop ladder code which takes advantage of each
machine tool’s specific application needs. A complete list of instructions is given in the GE Fanuc
PMC Model PA1/PA3/RA1/RA2/RA3/RB/RB2/RB3/RB4/RB5/RB6/RC/RC3/RC4/NB/NB2 Ladder
Language Programming Manual (publication no. B-61863E).

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 3

The Advantages of Ladder Language Programming

Designing a sequence program begins with creating a ladder diagram and there are two program entry
methods. One is the entry method with the mnemonic language (PMC instructions such as RD, AND
and OR). The other is the relay symbol method in which the sequence program is entered by using
the relay contact symbols and the functional instruction symbols of the ladder diagram. This can be
done using GE Fanuc’s FAPT ladder ladder language software package.

Ladder programming Mnemonic programming

RD X0.0
AND R10.1
OR X6.1
X0.0 R10.1 R20.3 Y0.0

vs. AND.NOT R20.3

WRT Y0.0

X6.1

Figure 3 - 4. Comparison of the two modes of program entry

So, if there are two methods of programming, why program using the relay symbols? Here are
several advantages ladder programming offers over mnemonic language programming:
1. A program can be understood and developed easily. By
visualizing the program as physical contacts on a ladder
relay, you can see the overall structure of as you progress.
You thereby reduce the effects of two characteristics
inherent to software: invisibility and intangibility.
2. A program error can be found easily. The cost of an error increases exponentially in the
software development cycle. The earlier you find your bugs, the less it’s going to cost you.
3. It serves as a powerful maintenance tool. When an operation error occurs, you can look at
the relay contacts in the ladder diagram to troubleshoot the problem.

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 3

Section 2 Installing the Startup Ladder

In order to load the ladder into your control, you have to use a PCMCIA card. The ladder files we
have provided are on a 3 ½” floppy disk and you must use a PC to copy the necessary file onto a card
which you supply.
There are two ladder files on the floppy disk. You only have to copy the one file which fits your
control:

1. If you have a 16i or 18i, please copy the file named 16_18.LAD
onto the PCMCIA card.
2. If you have a 21i, please copy the file named 21.LAD onto the PCMCIA card.

Note
If you haven’t turned off the control, turn off the control now before going any
further!

Now, follow this procedure to load the startup ladder from your PCMCIA card onto the control: In
order to make this easier to read, each action item is written in bold/underlined form.

1. Locate the PCMCIA card with the ladder file on it. Insert the card into the PCMCIA slot on
the front of the control to the left of the LCD.
2. Hold down the two rightmost soft keys and power up the control. If your control has the touch
screen display option, hold down the [6] and [7] hard keys simultaneously on the MDI panel
instead. This will bring up the SYSTEM MONITOR MAIN MENU. The cursor should be on
SYSTEM DATA LOADING (see Figure 3-5 below).

SYSTEM MONITOR MAIN MENU

1. SYSTEM DATA LOADING

2. SYSTEM DATA CHECK
3. SYSTEM DATA DELETE
4. SYSTEM DATA SAVE
5. SRAM DATA BACKUP
6. MEMORY CARD FILE DELETE
7. MEMORY CARD FORMAT

10. END
* * * MESSAGE * * *
SELECT MENU AND HIT SELECT KEY.

[SELECT] [ YES ] [ NO ] [ UP ] [ DOWN ]

Figure 3 - 5. System monitor main menu

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 3

3. In order to get around the screen and make selections, you will need to use the soft keys (or in
the case of a touch panel, the number keys on the MDI unit. Choose SELECT. There should be
one file listed with the cursor on it. This is the file you copied from the 3 ½” floppy disk to the
PCMCIA card (in this example, we are loading a ladder onto a 21i control).

SYSTEM DATA LOADING

[BOARD : MAIN]
FILE DIRECTORY
21.LAD 131488 1997-08-27 14:15
END

* * * MESSAGE * * *
SELECT FILE AND HIT SELECT KEY.

[SELECT] [ YES ] [ NO ] [ UP ] [ DOWN ]

Figure 3 - 6. System data loading screen

4. Choose SELECT. On the message portion of the screen at the bottom, you should see:
LOADING OK ? HIT YES OR NO.

5. Choose YES to save. When the file is saved onto the control, the message section will read:
LOADING COMPLETE. HIT SELECT KEY.

6. Choose SELECT.
7. Cursor down to END.
8. Choose SELECT. This will bring you back to the SYSTEM MONITOR MAIN MENU illustrated
in Figure 3-5 on the previous page.
9. Cursor down to END.
10. Choose SELECT. The following message will be blinking at the bottom of the LCD:
ARE YOU SURE ? HIT YES OR NO.

11. Choose YES and the control will boot up with the new ladder.

You have a working ladder loaded onto your control!

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 Chapter Powering Up the Entire System
4

Until now, we have set parameters and edited the ladder but we have done so by only powering-
up the control. Now we are finally ready to set the last group of parameters which will allow you
to bring up the other crucial element in our control system: the servo amplifiers.

The servo amplifiers are connected to the control by an optical cable called the Fanuc Serial
Servo Bus (FSSB). As you might have guessed, there are parameters related specifically to the
FSSB optical link between the control and the servo drives. This next section will discuss how to
go about correctly setting the FSSB parameters.

Note
The examples given in this section are a continuation of those from Chapter 2.
If you are using a 3-axis configuration (it doesn’t matter if you have a 16i, 18i,
or 21i), you can just enter the parameter values exactly as they appear in this
manual. If you are running more than three axes, make sure you follow the
directions carefully.

For parameter settings of different setup configurations, (such as a separate feedback device),
please refer to:

16i / 18i / 160i / 180i - Model A Parameter Manual (publication no. B-63010EN)
21i / 210i - Model A Parameter Manual (publication no. B-63090EN)

B-63003EN-2/01 4-1
 4

Setting FSSB parameters

Now we will go ahead and describe how to set the last grouping of parameters. When you are
finished with this section, you should be able to get the servo motors turning.

Servo Axis Number

This is the parameter which tells the control which motor is turning which axis. Back in chapter
2, we set this parameter value to -128 for all axes in order to get rid of an alarm. Now we need to
assign axis numbers to each motor. The axis numbers are assigned as follows:
1. If you have only one servo amplifier, the axis number is the same as the number of the
connector where you have your motor feedback cable plugged in. For example, if your
X-axis feedback is plugged in the slot ENC1 JF1, then you would enter the value “1” for
your servo axis number.
2. The axis number on the second amplifier would start where you ended on the first. Let’s
say that we have three axes and two amplifiers. Two axes were plugged into the first
amplifier and one in the second. Even though the one axis in the second amplifier plugs
into slot ENC1 JF1, it would be assigned the value “3” because it is the third axis.
In this 3-axis example, your parameter values should be changed to these:

1023 SERVO AXIS NUM. X 1

Z 2
C 3

Now, you will notice that the alarm messages screen pops up with this message:

000 PLEASE TURN OFF POWER

Just as we did in chapter 2, simply ignore this alarm and just cycle the power once when you have
set all of the basic parameters. To get back to the parameter screen, press [SYSTEM] followed by
(PARAM).

The FSSB Setting Mode

Set FMD to one. This means that you will manually enter values for parameter numbers 1023,
1905, 1910~1919, 1936, and 1937 (these are the FSSB parameters).

1902 FMD
0 0 0 0 0 0 0 1

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 4

Interface Between Servo Amplifier and Servo Software

In order to set FSL, there are five conditions which have to be satisfied. It can be fairly
confusing, and for a startup application, it is only important that the parameter is not set
incorrectly. An easy way to set this parameter is to follow these guidelines:

1. If the axis number is odd, enter “0”. The axis number is what you entered in parameter
1023.
2. If the axis number is even, enter “1”.

1905 FSL
X 0 0 0 0 0 0 0 0
Z 0 0 0 0 0 0 0 1
C 0 0 0 0 0 0 0 0

Address Conversion Table Values for Slaves

A slave is just a device such as a servo amplifier or pulse module which is connected to the
control via the FSSB. A maximum of ten slaves can be assigned to the control. A two-axis
amplifier has two slaves, while a three-axis amplifier has three slaves and so on.
There are ten consecutive parameters and each one is assigned to one slave. This means that
parameter 1910 is the address conversion table value for slave one, and parameter 1919 for slave
ten. In our example, we have three slaves.
Follow this procedure when connecting amplifiers (keep in mind that this applies to parameters
1910~1919):
1. When the slave is an amplifier, just subtract 1 from the value in parameter
1023 for each axis.
2. When there is no slave, set the parameter to 40.

1910 0
1911 1
1912 2
1913 40
1914 40
1915 40
1916 40
1917 40
1918 40
1919 40

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 4

1st and 2nd Pulse Modules

When we set parameter 1902, we mentioned that we had to manually set parameters 1936 and
1937 as well. These two parameters apply only when using separate feedback devices. Since we
don’t have any in our example setup, we’ll just leave these set to their default value of zero.

1936 X 0
Z 0
C 0

1937 X 0
Z 0
C 0

Enable Write Protect (Optional)

Now that you have set all of the startup parameters, you can choose to turn off the Parameter
Write Enable (PWE) bit and finally get rid of the alarm:
100 PARAMETER WRITE ENABLE

As we mentioned in Chapter 2, this is the built-in software write protect feature which will prevent
accidental changes to parameter values. However, since you will still need to enter values for the
parameters which are specific to your machine’s application, we recommend that you turn off
PWE after these have all been entered. If you turn off PWE, please remember that you cannot
change any parameter values until it is turned back on.

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 4

Powering up the Entire System

Precautions
The 16i/18i/21i machine tool control system is ready to be turned on now. Before continuing
here, you have to turn off power to the control.
Review these safety precautions first:
1. Confirm that the supplied cables are properly attached to
the appropriate connectors.
2. Check that all wiring to the power source is correct. This includes the 24V DC power
connections and the 200V AC power connections.
3. Make sure that the motors are properly secured but are not yet connected to the machine
load.
4. Check that all components are properly grounded.

Powering Up
There is a specific sequence for turning on the machine tool control system. Follow these steps in
order to bring up the servo drives and get the system running:
1. Turn on the 200V AC input power to the servo amplifiers.
2. Hit the ON switch on the operator’s panel. This turns on the 24V DC power to the
control, the operator’s panel connection unit, and the I/O modules.

Note
If you did not use a relay to connect the switching device on the operator’s
panel to the I/O power supply (as recommended in Chapter 1), you must turn
on the power to the Model A I/O units just when or before the power for the
control is turned on. For more information on the power on/off timing
requirements, refer to Section 4.2 in the I/O Unit Model A
Connection/Maintenance Manual (publication no. B-61813E).

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 4

Jogging the Servo Motors

If all of procedures were performed correctly until now, your control should come up with no
alarms (except for PARAMETER WRITE ENABLE maybe). You should now be able to get the
motors running. Press these sequence of keys on your GE Fanuc operator’s panel:
1. Press the JOG button on the operator’s panel first.
2. Next, press the X button.
3. Finally press the + button.

Troubleshooting Your System

If you weren’t successful in turning the motor, there is probably a parameter that was incorrectly
set somewhere or a loose connection that you might have overlooked.
The GE Fanuc CNC Technical Service Hotline will be more than glad to assist you in finding the
problem and help you complete your setup. Before you call the hotline, please make sure to do
the following things:
1. Know what type of control you have (16i-T, 16i-M, 18i-T, 18i-M, 21i-T, 21i-M)
2. Write down all drive types, spindle/servo amplifier model numbers, and motor model
numbers. You will be asked for this information.
3. Observe any alarm messages you may see on your display.
4. Observe any alarms on your power supply module and/or amplifier modules. You can
check the status by looking at the red LED display towards the top of each module.
5. Contact your local GE Fanuc Office (see next page for addresses) for further support.

Thank you for choosing the GE Fanuc 16i/18i/21i for

your precision machine tool control applications.

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